Vendor Says Its Vacuum-Overlay System Could Replace Auto Body Paint
Why paint a car body when you can wrap it instead?
Japan’s Fu-se Vacuum Forming says its automated film overlay process is faster, more energy efficient and results in a coating that’s at least as durable as paint.
Fu-se’s thermoform system starts with the TOM (Three-dimensional Overlay Method) it developed 20 years ago. Its machines are being used in multiple industries to coat everything from electrical appliances and personal electronics to vehicular interior trim, door handles and mirror housings.
Fu-se Vacuum Forming’s system (Image: Fu-se)
The latest iteration of TOM has been scaled up to coat components measuring as large as about 4x7 feet—or use the same size sheet to coat multiple small parts simultaneously. Fu-se is touting the new system as an alternative to painting body outer panels.
How It Works
Other companies market films that take the place of paint, of course. But applying them to complexly shaped parts can be difficult. Fu-se says its vacuum system and special film formulation overcomes that issue, while making the application process much faster.
The prototype system loads one or more parts to be coated into the lower half of a chamber that is covered by a secured sheet of film. The top half of the chamber is then lowered to create a pressure-sealed container.
Near-infrared heaters warm the film as a vacuum is formed on both sides of the film. When the proper film temperature is achieved, the top half of the chamber is flooded with compressed air, pushing the film down and onto the parts.
The application itself is completed in less than one second. An adhesive layer in the film anchors the material to the parts and hardens the film as it cools.
Japan’s Kyowa Leather Cloth supplies the high-tech film. The company concedes that its material costs 2-3 times as much as paint. Fu-se’s new automated system isn’t enough to close the cost gap.
Fu-se demonstration car
On the other hand, Kyowa notes, its film can be given the texture and appearance of cloth, wood, woven carbon fiber and other materials. The feature offers new appearance options for vehicle exteriors.
Fu-se is showing prototypes of its system to carmakers now, offering to customize it to suit customer needs. The supplier says it also may offer access to its technology for a licensing fee.
Ram Truck chief exterior designer Joe Dehner talks about how they’ve developed the all-new pickup. “We’ve been building trucks for over 100 years,” he says. “Best I could come up with is that this is our 15th-generation truck.”
According to Kunihiro Hoshi, chief engineer for the GX 470: “Three of my top goals were to create a body-on-frame vehicle with sweeping off-road performance and unibody-like on-road capability, and, of course, it had to meet the Lexus quality standard.” He met his goals. But why would anyone want to bang this vehicle around on rocks?
Generally, when OEMs produce aluminum engine blocks (aluminum rather than cast iron because cast iron weighs like cast iron), they insert sleeves into the piston bores—cast iron sleeves.